U.S. patent application number 17/249660 was filed with the patent office on 2021-07-22 for drilling rig.
The applicant listed for this patent is NATIONAL OILWELL VARCO NORWAY AS. Invention is credited to Erik Haavind, Frode Jensen, Hugo Leonardo Rosano, Stig Vidar Trydal.
Application Number | 20210222519 17/249660 |
Document ID | / |
Family ID | 1000005464701 |
Filed Date | 2021-07-22 |
United States Patent
Application |
20210222519 |
Kind Code |
A1 |
Rosano; Hugo Leonardo ; et
al. |
July 22, 2021 |
DRILLING RIG
Abstract
A system comprising a drilling rig having a rig floor, a
derrick, a master control computer system and at least one camera,
the at least one camera capturing a master image of at least a
portion of the rig floor, sending the master image to the master
control computer, the master control computer system mapping said
master image into a model to facilitate control of items on said
drilling rig.
Inventors: |
Rosano; Hugo Leonardo;
(Kristiansand, NO) ; Trydal; Stig Vidar; (Sogne,
NO) ; Haavind; Erik; (Kristiansand, NO) ;
Jensen; Frode; (Kristiansand, NO) |
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Applicant: |
Name |
City |
State |
Country |
Type |
NATIONAL OILWELL VARCO NORWAY AS |
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Family ID: |
1000005464701 |
Appl. No.: |
17/249660 |
Filed: |
March 9, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15526616 |
May 12, 2017 |
10961825 |
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PCT/GB2015/053458 |
Nov 13, 2015 |
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17249660 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H04N 13/271 20180501;
E21B 19/00 20130101; G06K 9/627 20130101; H04N 13/243 20180501;
F16P 3/142 20130101; G06K 9/00771 20130101; G06K 2209/19 20130101;
E21B 41/0092 20130101 |
International
Class: |
E21B 41/00 20060101
E21B041/00; E21B 19/00 20060101 E21B019/00; F16P 3/14 20060101
F16P003/14; G06K 9/62 20060101 G06K009/62; H04N 13/243 20060101
H04N013/243; H04N 13/271 20060101 H04N013/271; G06K 9/00 20060101
G06K009/00 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 14, 2014 |
GB |
1420292.3 |
Claims
1. A system for mitigating collisions on a drilling rig, the
drilling rig comprising a rig floor and a derrick, the system
comprising a plurality of cameras, each camera of said plurality of
cameras capturing an image of a zone on a rig floor in real time
and sending the image to a master computer system, the master
computer system processing said image of the zone and based on the
content of said image allow or disallow an item to move into or
within a particular part of said zone, wherein at least one item
image is stored in a memory of the master computer system, the
master computer system scanning said image for items to identify
said items using said item image as a comparison and wherein an
unsafe zone is stored in the master control system for said
item.
2. The system of claim 1, wherein at least one of said plurality of
cameras is mounted in the derrick providing a plan view of the rig
floor.
3. The system of claim 1, further comprising the step of the master
computer system plotting a location for each identified item on a
map.
4. The system of claim 3, wherein an in-use unsafe zone is stored
in the master control system for each of said at least one
item.
5. The system of claim 1, the master control computer system
provided with real-time data indicating if said item is
operating.
6. The system of claim 1, further comprising a plurality of item
skids moving on said rig floor.
7. The system of claim 6, wherein each item skid comprises at least
one information gathering device.
8. A system for mitigating accidents on a drilling rig, the
drilling rig comprising a rig floor and a derrick, the system
comprising a plurality of cameras, each camera of said plurality of
cameras capturing an image of a zone on a rig floor in real time
and sending the image to a master control computer system, the
master control computer system processing said image of the zone
analysing said image to detect the presence of a rig hand, the
master control system having a map of unsafe zones about items on
the drilling rig and assessing if the rig hand is within said
unsafe zone and based on said assessment allowing or disallowing at
least one of said items to operate in or be conveyed into said
unsafe zone.
9. The system of claim 8, wherein said image is analysed by said
master control computer system to identify said items on said rig
floor and locates said items on said the map of unsafe zones.
10. The system of claim 9, wherein said analysis comprises the step
of scanning the image for item images stored in a memory.
11. The system of claim 8, wherein a default unsafe zone is stored
in said master control computer system for each of said items.
12. The system of claim 8, wherein said master control computer
system comprises an algorithm to look for a rig hand feature.
13. The system of claim 8, wherein the rig floor comprises a
plurality of entrance points further comprising at least one camera
located with a field of view directed at each entrance points of
the plurality of entrance points to obtain images of rig hands
passing through said entrance, wherein said image is sent to said
master control computer system, whereupon the master control
computer system executes an algorithm to assess when a rig hand
enters or exits said entrance.
14. A system for mitigating collisions on a drilling rig, the
drilling rig comprising a rig floor and a derrick, the system
comprising a plurality of cameras, each camera of said plurality of
cameras capturing an image of a zone on a rig floor in real time
and sending the image to a master computer system, the master
computer system processing said image of the zone and based on the
content of said image allow or disallow an item to move into or
within a particular part of said zone, wherein at least one item
image is stored in a memory of the master computer system, the
master computer system scanning said image for items to identify
said items using said item image as a comparison and plotting a
location for each identified item on a map.
15. The system of claim 14, wherein at least one of said plurality
of cameras is mounted in the derrick providing a plan view of the
rig floor.
16. The system of claim 14, wherein a default unsafe zone is stored
in said master computer system for each of said at least one
item.
17. The system of claim 14, wherein an in-use unsafe zone is stored
in the master control system for each of said at least one
item.
18. The system of claim 14, the master control computer system
provided with real-time data indicating if said item is
operating.
19. The system of claim 14, further comprising a plurality of item
skids arranged on a network of rails the plurality of item skids
moving on said network of rails around said rig floor, each item
skid comprising at least one information gathering device wherein
the item skids are.
20. The system of claim 14, wherein said camera is a range imaging
camera.
Description
[0001] The present invention relates to a drilling rig and a system
of operating a drilling rig and particularly, but not exclusively
to a system for mitigating collisions on a drilling rig, a system
for mitigating accidents on a drilling rig and a system for
monitoring the health of tools on the rig floor.
[0002] In the drilling of a wellbore a drill bit is arranged in a
bottom hole assembly on the lower end of a drill string. The drill
bit is rotated to bore a hole in a formation. The formation may be
below water or may be dry land. An upper end of the drill string
passes through an opening in a drill floor of a drilling rig. The
opening is known as well centre. The drill string is constructed on
a drilling rig and then lowered into the hole using a wireline
drawn-in and let-out by a winch known as a drawworks. The wireline
passes over a crown block fixed to the top of a derrick, and passes
down to a travelling block which travels up and down within the
derrick to raise or lower joints of drill pipe and/or the entire
drill string.
[0003] The drill bit is, at least initially, rotated by rotation of
the drill string. The drill string may be rotated by a rotary table
arranged at well centre in the drill floor. In this case, a swivel
is hooked on to the travelling block, which has an elevator
attached thereto in which the drill string is held for lowering and
raising. Alternatively or additionally, the drill string may be
rotated by a top drive movable up and down a track in a derrick of
the drilling rig. The travelling block is connected to the top
drive to raise and lower the top drive along the track. A top drive
elevator depends from the top drive on bails. As the hole is
drilled, joints of drill pipe are added to the drill string to
allow the drill bit to drill deeper into the formation. The joints
of drill pipe are usually added in stands of two or more usually
three joints. The stands of drill pipe are made up off well centre
in a mouse hole or powered rat hole. The stands are made up using
an iron roughneck or: a separate spinner to run threaded pin ends
of a upper joint of drill pipe into corresponding threaded boxes of
a lower joint of drill pipe to make a connection; and a tong to
torque the connection. Pipe handling apparatus moves joints of pipe
from a pipe rack into alignment with the mouse hole or rat hole.
Another pipe handling apparatus moves the stand of dill pipe
directly to well centre for connection to the drill string or into
a rack comprising slots defined by fingers in an array known as a
finger board for buffer storage, such a rack and pipe handling
apparatus are disclosed in US-132-8550761, the disclosure of which
is incorporated herein for all purposes. The stand of drill pipe is
then connected to the string of drill pipe suspended in the hole.
The connection is made using an iron rough neck or a separate
spinner and tongue.
[0004] It is also know from WO 2011/135311 to have a system for
determining the position of a downhole drill pipe relative to an
iron roughneck. The system comprises: an imaging means arranged to
capture an image of the drill pipe in a region of the pipe for
engagement by the device; and a processor operable to analyse said
captured image and to determine therefrom the position of the drill
pipe relative to the iron roughneck.
[0005] The drill string is removed from the well, in a procedure
known as "tripping-out". Typically, the top drive elevator lifts a
stand length of drill pipe out of the hole. The spider in the rig
floor at well centre prevents the rest of the drill string from
falling downhole. The stand length of drill pipe is disconnected
from the drill string using an iron roughneck. The stand is
"set-back" in the finger board.
[0006] To improve the integrity of the hole, the hole may be lined
with casing. A string of casing is lowered into the hole and hung
from a wellhead or template on the surface of the formation. During
construction of the casing string a section of casing is added to
the casing string as it is lowered into the hole. The section of
casing is moved into alignment with a pipe handling apparatus or an
elevator is used to lift the upper end from a conveyor so that the
lower end swings into alignment with well centre and the casing
string suspended in the hole. The section of casing is then
connected to the string of casing suspended in the hole. The
connection is made using: a casing iron rough neck, separate casing
spinners and tongues; or using a casing running tool (CRT) using
rotation of the top drive whilst torque is resisted by the casing
string being held in a spider in the floor of the drilling rig.
Once the string of casing is complete, it is hung from the template
or wellhead. Centralizers may be used to centre the casing in the
hole.
[0007] The casing may be cemented in place.
[0008] The drill bit and drill string are "tripped-in" to the well.
The drill bit on a BHA and subsequently stands of drill pipe from
the finger boards are moved to well centre one at a time using the
pipe handling arm and connected in the same procedure as described
above, except for the fact that the hole is pre-drilled and cased,
so the procedure is carried out at a much quicker pace than when
drilling.
[0009] Drilling then continues. When the drill string is long, it
is difficult to transfer torque from the top drive or rotary table
to the drill bit. A mud motor may be used. The mud motor is
installed near to the bottom hole assembly. The circulation of
drilling mud through the mud motor rotates the drill bit.
[0010] More, smaller diameter casings may be installed and cemented
in place as the hole is drilled further. Furthermore, a liner may
be set, which is a casing which is not tied back to the wellhead,
but hung from the lower end of a previously hung casing.
[0011] Lateral holes may be formed from the main hole, using tools
such as window mills and whipstocks. The lateral holes can extend
several kilometres from the main hole.
[0012] Specialist tools may be required during the drilling
process, such as a continuous circulation tool, such as the one
shown in WO-98/16716 and WO 2009/093069. These tools are brought up
to the rig floor and placed at well centre. The continuous
circulation tool is then connected into the drill string between
the rig floor and an upper sub connected to a top drive. These
tools allow a continuous circulation of drilling mud whilst dill
pipe is added or taken away during tripping and thus maintains a
constant pressure in the wellbore.
[0013] The hole may then be cleaned using cleaning tools on the end
of a drill string and made ready for receiving oil from the
formation, known as the production phase.
[0014] Various operations can be carried out during the production
phase, such as work over and well stimulation operations to attempt
to obtain more oil from the well. These operations may be carried
out using coiled tubing and tools connected thereto. These
operations may be carried out from the well head or the rig
floor.
[0015] Thus several standard operations are carried out during the
construction and production phases over the life of a well, such
as: drilling phase; tripping-out phase; casing phase; tripping-in
phase; completion phase; production phase; and intervention phase;
as well as specialist operations. Different tools are required for
each phase and thus tools are changed over on the rig floor between
phases.
[0016] The inventors have also observed that if a tool used on a
rig floor becomes faulty, the rig operations often have to cease
whilst men retrieve and replace the faulty tool. Significant down
time can occur. This is particularly, but not exclusively relevant
in a dual derrick system, where operations switch from drilling, to
casing to completion etc. very quickly and frequently, thus a lot
of time is lost as "flat time", whilst changing the configuration
of tools at the well centres.
[0017] The inventors have observed that there is a risk of
collision between tools, equipment and other items on a rig floor
of a drilling rig. The inventors have also observed that drillers
and tool pushers overly estimate the size of items such as tools,
pipe and equipment moving on around a drilling rig in order to
avoid collisions. Furthermore, the speed at which tools, equipment
and other items are moved around a rig floor is often overly
reduced by the drillers and tool pushers to mitigate collisions.
Furthermore, the inventors have observed that rig hands on the rig
floor are in potential danger when in close proximity to tools in
operation and when tools and equipment are moved around a drilling
rig.
[0018] In accordance with the present invention there is provided a
system for operating a drilling rig, the system comprising a
drilling rig having a rig floor, a derrick, a master control
computer system and at least one camera, the at least one camera
capturing a master image of at least a portion of the rig floor,
sending the master image to the master control computer, the master
control computer system mapping said master image into a model for
a zone management system.
[0019] Preferably, the master image is constructed from a plurality
of sub-images, each sub-image captured by a camera.
[0020] Preferably, the master image is analysed by the master
control computer system to obtain three dimensional model.
Advantageously, the master image comprises a grey scale contrast or
colour contrast, preferably the master control computer system
analysis said contrast to produce said model. Preferably, the
camera captures range data, the range data used to defining points
for said model.
[0021] Preferably, the model is created in real time.
Advantageously, the master image is captured at least once every
minute and an updated model created in real time. Preferably, the
master image is captured at least once every second and an updated
model created in real time. Advantageously, the master image is
captured at least ten times every second and an updated model
created in real time. An algorithm can be used to reduce the need
for computing power and increasing speed of processing by
identifying areas of the model which have changed and only updating
the changing parts of the model, for example using block matching
used in MPEG-2.
[0022] Advantageously, the model is used in a collision mitigation
system. Preferably, the model is used in a system for mitigating
accidents on a drilling rig. Advantageously, the model is used in a
health check system.
[0023] The present invention also provides a system for mitigating
collisions on a drilling rig, the drilling rig comprising a rig
floor and a derrick, the system comprising a plurality of cameras,
each camera of said plurality of cameras capturing an image of a
zone on a rig floor in real time and sending the image to a master
computer system, the master computer system processing said image
of the zone and based on the content of said image allow or
disallow an item to move into or within a particular part of said
zone.
[0024] Advantageously, at least one of said plurality of cameras is
mounted in the derrick providing a plan view of the rig floor.
Preferably, the camera is arranged on a track and movable
therealong. Advantageously, the camera is movable on a universal
joint, which may be provided with means such as a grub screw to
lock the universal joint in one position. The camera may be movable
by remote control to select a field of vision.
[0025] Advantageously, the master computer system scans said image
for items. Preferably, the analysis comprises the steps of scanning
the image for items, each item having an item image stored in a
memory of the master computer system. For example, an item image is
a top plan view of an iron roughneck, well centre, a spider, a
spider skid, a dog house skid etc. Advantageously, the system
further comprises the step of the master computer system plotting a
location for each identified item on said map. Advantageously, a
default unsafe zone is stored in said master computer system for
each of said at least one item image. Preferably, an in-use unsafe
zone is stored in the master control system for each of said at
least one item image, advantageously the master control computer
system is provided with realtime data indicating if said item is
operating and preferably particulars of the type of operation.
[0026] Preferably, the system comprises a plurality of item skids
moving on said rig floor. Advantageously, each item skid comprises
information gathering devices, such as at least of a: location
sensor, orientation sensor, ID tag reader; weight sensor; memory,
where preferably information from the information gathering devices
is collated and processed by said master computer system.
Preferably, the skid further comprises an on-board computer system
for collating data information from said plurality of information
gathering devices.
[0027] Advantageously, the skids are arranged on a network of
rails.
[0028] Preferably, said image is digital, although may be an
analogue image. Preferably, a high definition analogue camera is
used in combination with a range data collecting apparatus, which
may be light based, such as a time of light laser, differential
path or be sound based, such as sonar. Advantageously, said image
comprises or is wholly built up from range data, such that a three
dimensional image is captured and sent to the master computer
system. Preferably, the range data is measured for each hundred
square millimetres of the zone.
[0029] Advantageously, the camera is a range imaging camera.
Preferably, the camera is a range imaging camera is one of the
following types: time-of-flight, stereo triangulation, sheet of
light triangulation type, structured light type.
[0030] Preferably, the image is captured every one to five minutes.
Advantageously, the image is captured every ten seconds to sixty
seconds. Preferably, the image is captured every one to ten second.
Advantageously, image is captured between fifty and one times per
second.
[0031] Most equipment moving around the rig is equipped with
sensors that report position and intended motion to a master
computer control system.
[0032] Rig hands on a rig floor are needed to fulfil a number of
tasks, such as moving and operating tools, inspection, maintenance,
problem solving etc. Rig hands are managed by the driller or tool
pusher, but not to the extent their position on the drilling rig is
always known. Thus their location at any point in time is not
necessarily known by the driller, tool pusher or master computer
control system running automated operations and tools on the
drilling rig.
[0033] The rig hands always wear safety helmets on the rig floor.
This is a mandatory safety requirement and rig hands are used to
following this procedure. A location device and transmitter may be
installed in the rig hand's safety helmet to transmit a signal back
to a receiver linked to the master computer control system. The
master computer control system is provided with an algorithm to
assess the rig hand's location on the rig floor which is
continuously monitored. In this way, potentially dangerous
operations can be delayed or stopped if the rig hand is within an
unsafe zone at the location of and around the potentially dangerous
operation. The inventors have observed that this system is very
useful, but could benefit from a more robust alternative or
additional system. In accordance with another aspect of the present
invention there is provided a system for mitigating accidents and
optionally, mitigating down time on a drilling rig, the drilling
rig comprising a rig floor and a derrick, the system comprising a
plurality of cameras, each camera of said plurality of cameras
capturing an image of a zone on a rig floor in real time and
sending the image to a master control computer system, the master
control computer system processing said image of the zone analysing
said image to detect the presence of a rig hand, the master control
system having a map of unsafe zones about items on the drilling rig
and assessing if the rig hand is within said unsafe zone and based
on said assessment allowing or disallowing an item to operate in or
be conveyed into said unsafe zone.
[0034] A rig hand has a number of identifiable signatures which do
not vary considerably from one rig hand to another, but do vary
considerably from other objects found on a rig floor. Such a
feature is the helmet. Another feature is the face of the rig hand.
Another is the rig hands heat signature.
[0035] Preferably, the map of unsafe zones is obtained by analysing
an image obtained from a camera, which may be different or the same
cameras. Advantageously, the analysis comprises the steps of
scanning the image for items which stored in a memory. Preferably,
the scanning comprises holding at least one item image and scanning
said image for said at least one item image, and advantageously
plotting a location for each identified item on said map.
Advantageously, a default unsafe zone is stored in said master
control computer system for each of said at least one item image.
Preferably, an in-use unsafe zone is stored in the master control
system for each of said at least one item image, advantageously the
master control computer system is provided with realtime data
indicating if said item is operating and preferably particulars of
the type of operation.
[0036] Optionally, the camera is a heat sensing camera for
optionally identifying inanimate objects and optionally identifying
rig hands. The master computer control system may comprise an
algorithm for filtering out parts of the obtained images which are
not likely to be rig hands. For example, the structure of the
drilling rig has a heat signature which is very different to that
of a rig hand and thus the master computer control system filters
out large parts or all of the image. Certain movable machines, such
as an iron roughneck, has a heat signature which is very different
to that of a rig hand and thus the master computer control system
filters out large parts or all of the image. Furthermore, certain
known items are static and always present of a rig floor, such as a
derrick, towers, racks, drawworks, dog house etc. Details of these
known items may be contained in a known items database. The
computer system may be provided with an additional algorithm to
filter out parts of the image of those details held in the known
items database. The parts of the image that are left are then
analysed using further algorithms. The system thus comprises or
further comprises a heat sensing camera such as a thermal imaging
camera. The master computer control system may further comprise a
database of known heat signature profiles for machines or any other
object likely to be found on a rig floor. The master control
computer system may be provided with an algorithm to compare the
obtained heat signature profiles with those in the database to
discount them from being a rig hand.
[0037] Rig hands generally have an identifiable heat pattern
signature. The master computer control system is optionally
provided with an algorithm to assess if there is a heat pattern
which is indicative of a rig hand. The master computer control
system is also provided with an algorithm to assess the location of
the heat pattern indicative of a rig hand on the rig floor.
Optionally, the thermal imaging capers is provided with a range
imaging device, which facilitates obtaining a location co-ordinate
on the rig floor.
[0038] A rig hand has certain identifiable visible signatures which
do not vary considerably from one rig hand to another. Such a rig
hand feature is a helmet, face or facial features. It is thus
preferable for the system to have a camera for receiving reflected
visible light information to assess a visible signature of at least
part of the rig hand. Optionally, the system also comprises a heat
sensing camera for detecting a heat signature of a rig hand and/or
to discount items in the field of view of the camera of items not
matching the heat signature of the rig hand. Such items are
inanimate objects, such as structure in the rig floor area and
operating machines. If the two results (light and heat sensing) are
positive, it is highly likely that the system has identified a rig
hand. If only one of the two cameras (light and heat sensing)
identifies a rig hand, the system assumes there is indeed a rig
hand in that location. In this way, the system has more redundancy
and less likely to allow an operation within an unsafe zone to be
carried out.
[0039] For example, a rig hand may be wearing a fire resistant suit
which may be highly insulated and thus not allow a rig hand's heat
signature to be detected by the heat sensing camera. However, the
light sensing camera will detect the rig hand from his outline
profile signature or part of the outline, for example, the outline
of his helmet. Furthermore, in inclement weather conditions, such
as thick fog or heavy rain, the light sensing camera may not be
able to identify the outline profile of the rig hand, but will be
able to identify the rig hand's heat signature.
[0040] The master computer control system may be provided with an
algorithm to keep a tally of rig hands on the rig floor.
Optionally, the master computer control system also comprises an
algorithm to compare the tally with the number of rig hands located
using the system of the invention on the rig floor. If the numbers
are not equal, a further rig hand signature is looked for or the
tool pusher or driller is alerted. The master computer control
system may also be provided with the number of the helmet location
devices active on the rig floor as a further check.
[0041] Analysing images in series and keeping a continuous update
of rig hand's location will also add robustness to the preferred
solution. Most drilling rigs have specific walking rails or
platforms to enter and exist working areas. Start tracking on this
defined corridors or gates would remove uncertainty on the topic of
person vs machine. A system that passes people information position
from one image frame to the other will propagate location from
areas of high certainty to those of higher uncertainty.
[0042] Information from the rig hand tracking system can then be
combined with that of all the machine positions for a complete
anti-collision system. Therefore, mitigating accidents and reducing
downtime.
[0043] Optionally, the camera may also captures wavelengths in the
infrared range. Infrared reflectors may be worn by the rig hands
for producing reflected light for the camera to detect and produce
an image thereof.
[0044] In accordance with another aspect of the invention, there is
provided a system for mitigating accidents on a drilling rig, the
drilling rig comprising a rig floor and a derrick and a plurality
of entrances to the rig floor the system comprising at least one
camera at each of the plurality of entrances, each camera capturing
an image of a rig hand or item passing through the respective
entrance in real time and sending the image to a master control
computer system, the master control computer system processing said
image of the rig hand or object executing an algorithm to assess if
said image comprises the presence of a rig hand, the master control
system maintaining a tally of rig hands on the rig floor.
Optionally, a further camera may be required for assessing when a
rig hand exits the entrance to the rig floor.
[0045] In accordance with another aspect of the present invention
there is provided a system for monitoring the health of a tool on a
drilling rig the system comprising a camera positioned to monitor
said tool and a health check computer control system having at
least one reference image stored therein, the camera sending a real
time image of said tool to said health check computer control
system, said master computer control system comparing said real
time image with said at least one reference image, noting
differences, and sending a signal to a health check computer if the
difference is likely to affect the health of the tool.
[0046] Advantageously, the health check computer sends a signal to
the tool to cease operation. Preferably, the health check computer
sends a signal to a group of tools including the tool to cease
operation. Advantageously, the health check computer sends a signal
to an interface, such as a visual display, to alert the driller or
tool pusher or operator of the tool if a difference is noted which
is likely to affect the health of the tool.
[0047] Advantageously, the health check computer is loaded with
algorithms to difference is likely to affect the health of the
tool. Preferably, the algorithms comprise a colour differentiation
algorithm. Advantageously, the health check camera includes a range
measuring apparatus, the system comprising measuring and recording
range data in said reference image, the algorithms comprising a
range comparison algorithm for assessing differences in range.
Advantageously, the range data comprises relative ranges, such as
the depth of a crack which was not apparent in the reference
image.
[0048] Preferably, the tool is one of an: elevator; top drive
system, iron roughneck; crown block; travelling block; cranes; pipe
tail handlers; equipment skids; tool skids; dog house skids.
[0049] Range imaging cameras are used to create a three dimensional
representation of the rig floor. A number of cameras are installed
around the rig floor.
[0050] The range imaging cameras may be a stereo triangulation type
in which two spaced cameras are pointed to the same spot on the rig
for determining the depth to points in the scene.
[0051] The range imaging camera may be a sheet of light
triangulation type wherein the zone is illuminated with a sheet of
light which creates a reflected line as seen from the light source.
From any point out of the plane of the sheet the line will
typically appear as a curve, the exact shape of which depends both
on the distance between the observer and the light source, and the
distance between the light source and the reflected points. By
observing the reflected sheet of light using a high resolution
camera and knowing the positions and orientations of both camera
and light source, it is possible to determine the distances between
the reflected points and the light source or camera. By moving
either the light source (and normally also the camera) or the scene
in front of the camera, a sequence of depth profiles of the scene
can be generated. These can be represented as a 2D range image.
[0052] The range imaging camera may be a structured light type,
wherein the zone is flooded with a specially designed light
pattern, structured light, depth can be determined using only a
single image of the reflected light. The structured light can be in
the form of horizontal and vertical lines, points or checker board
patterns.
[0053] The range imaging camera may be a time-of-flight technique,
wherein a light pulse is used to, preferably with the entire zone
captured with a single light pulse, although point-by-point
rotating laser beam is an option. Time-of-flight cameras capture
the whole zone in three dimensions with a dedicated image sensor,
and therefore have no need for moving parts. A time-of-flight laser
radar with a fast gating intensified CCD camera may achieves
millimetre depth resolution. With this technique a short laser
pulse illuminates the zone, and the intensified CCD camera opens
its high speed shutter only for a few hundred picoseconds. The 3D
information is calculated from a 2D image series that was gathered
with increasing delay between the laser pulse and the shutter
opening.
[0054] Preferably, the rig floor is located in a drilling rig.
Advantageously, the rig floor is locate in one of: a drill ship;
FPSO; SWATH; tensioned leg platform; and land rig.
[0055] The present invention also provides a system comprising at
least one range imaging camera arranged in a rig structure of a
drilling rig and a master control computer system, the at least one
range imaging camera capturing images and ranges of a rig floor
said images and ranges uploaded to a master computer control
system.
[0056] For a better understanding of the present invention,
reference will now be made, by way of example, to the accompanying
drawings, in which:
[0057] FIG. 1 is a perspective view of part of a drill ship having
a rig floor in accordance with the present invention showing inter
alia a network of rails and plurality of skids, the view as seen
from a camera forming part of the invention;
[0058] FIG. 2 is a schematic top plan view of part of the drill
ship shown in FIG. 1;
[0059] FIG. 3 is a side view of a spider skid for use on the
network of rails;
[0060] FIG. 4 is a top view of the spider skid shown in FIG. 3 with
a spider thereon;
[0061] FIG. 5 is a side view of the spider skid shown in FIG. 3
with a spider thereon;
[0062] FIG. 5A is a side schematic view of part of the spider skid
shown in FIG. 5, approaching a parking spot on a rig floor of the
drill ship shown in FIG. 1;
[0063] FIG. 5B is a side schematic view of part of the spider skid
shown in FIG. 5, at a parking spot on a rig floor of the drill ship
shown in FIG. 1;
[0064] FIG. 5C is a flow diagram showing data flowing into an
on-board data gathering computer and collating an information
package;
[0065] FIG. 6 is a top view of the spider skid as shown in FIG. 4
and a crane skid on adjacent tracks of the network of rails as
shown in FIG. 1 at well-centre;
[0066] FIG. 6A is a top plan view of the crane skid shown in FIG. 6
on a track with a stationary unsafe zone marked in dashed and an
additional unsafe zone marked in dash dot line;
[0067] FIG. 7 is a side view of the crane skid shown in FIG. 6 in a
stowed position for transportation along the network of rails shown
in FIG. 1;
[0068] FIG. 8 is a side view of the crane skid shown in FIG. 6 with
a jib in an extended position in use whilst on the track of network
of rails;
[0069] FIG. 9 is a flow diagram showing data flow for a collision
mitigation system;
[0070] FIG. 10 is a flow diagram showing data flow for a further
collision mitigation system;
[0071] FIG. 11 is a flow diagram showing data flow for a system for
mitigating accidents between rig hands and tools carried on or
forming part of skids;
[0072] FIG. 12 is a side view of a diverter skid for use on the
network of rails shown in FIG. 1 the diverter skid having a
diverter thereon and a lifting apparatus for lifting the diverter
on to and from the diverter skid;
[0073] FIG. 13 is a top view of the diverted skid shown in FIG.
12;
[0074] FIG. 14 is a side view of part of a land drilling rig in
accordance with the present invention having a rig floor, the
drilling rig in a first stage of operation;
[0075] FIG. 15 is a side view of the drilling rig shown in FIG. 14
in a second stage of operation;
[0076] FIG. 16 is a top plan view of the rig floor and cat walk of
the drilling rig shown in FIG. 14;
[0077] FIG. 17 is a view of the rig floor shown in FIG. 14 in a
third stage of operation from the view point of a camera forming
part of a system in accordance with the present invention;
[0078] FIG. 17A is a flow diagram for a system for mitigating
accidents on a rig floor;
[0079] FIG. 17B is a side view of a drilling rig, like the drilling
rig shown in FIG. 15 incorporating rig hand safety apparatus;
[0080] FIG. 17C is a schematic view of one of the rig hand safety
apparatus shown in FIG. 17B;
[0081] FIG. 17D shows a part of a rig floor area provided with a
further embodiment of a rig hand safety apparatus of the present
invention;
[0082] FIG. 17E shows a plan view of a rig floor provided with a
multiplicity of rig hand safety apparatus of the type shown in FIG.
17D; FIG. 18 is a perspective view of a top drive system of the
present invention on a track forming part of the derrick shown in
FIG. 14, the top drive system comprising an elevator system in
accordance with the present invention;
[0083] FIG. 19 is a side view of the top drive system shown in FIG.
18;
[0084] FIG. 20 is a perspective view of the elevator system as
shown in FIG. 18;
[0085] FIG. 21 is a perspective view of an iron roughneck system in
accordance with the present invention, having an iron roughneck at
well centre with an iron roughneck handling arm in a retracted
position;
[0086] FIG. 22 is a perspective view of the iron roughneck system
shown in FIG. 21 with the iron roughneck handling arm in an
extended position;
[0087] FIG. 23 is a flow diagram showing steps in a method of
checking the health of a piece of equipment on a drilling rig.
[0088] Referring to FIGS. 1 and 2, there is shown part of a drill
ship, generally identified by reference numeral 1 having a rig
floor 2 in accordance with the present invention. The perspective
view of FIG. 1 is as seen from a camera 26 on a rig structure in an
aft of the drill ship 1 of amidships looking towards the bow 3. The
drill ship 1 has two derricks 4 and 5 arranged on a starboard side
of the drill ship 1, each with a corresponding well centre 6 and 7
located substantially along a centreline 8 of the drill ship 1. The
top plan view of FIG. 2 is as seen from a camera 28 looking down
from a high point on the derrick mast 4 and 5. The camera 28 may
comprise several cameras, the images obtained from which are
combined to form a composite image. This may be beneficial to
obtain a view of the rig floor 2 without obstruction from
structures rising therefrom. A pipe handling and make-up structure
9 is arranged on a port side of the drill ship 1. The rig floor 2
is arranged between and about the two derricks 4 and 5. The rig
floor 2 surrounds the two derricks 4 and 5. A network of rails 10
is arranged in the rig floor 2. The network of rails 10 comprise a
plurality of straight tracks 11 to 19. Each of tracks 11 to 19
comprises a plurality of pairs of rails, such as pairs of rails 20,
21.
[0089] A plurality of specific item skids are shown in FIGS. 1 and
2 on the network of rails 10. A pipe tail handler skid 30, a dog
house skid 31, a riser handling arm skid 32, a rotary table skid
33, a coiled tubing skid 34 and a well intervention coiled tubing
injector skid 35.
[0090] The network of rails 10 comprises track 11 to 19 in a layout
which will be suitable for a rig floor on a drill ship 1. All
tracks 11 to 19 may be used to route particular skids between
destinations. However, each track 11 to 19 has a main use. The
tracks each have a pair of parallel rails spaced approximately 3.2
m.
[0091] Tracks 11 and 12 lead around the back of the derricks 4 and
5 and past a downhole tool storage area 22 are used to move
particular skids from a bow storage area 23 of the drill ship 1 to
the main rig floor 2.
[0092] Track 13 is used mainly as a storage area 40 for item skids
which may be used in an upcoming operation.
[0093] Track 14 is used mainly as an access route to guide skids
from the storage area 40 to or close to well-centres 6 and 7. Track
14 also leads to a Christmas Tree elevator 44 located on the port
side of the rig floor 2. Christmas Trees (not shown) are located in
an area below the rig floor 2 on a Christmas Tree skid (not
shown).
[0094] Track 15 is used mainly as an access route to guide skids
from the bow storage area 23 to or close to the well-centres 6 and
7. Tracks 14 and 15 are also used for locating a dog house skid 31,
which provide the driller and tool pusher good views of the
well-centres 6 and 7.
[0095] Track 16 is used mainly as an access route to guide skids
from the storage area 40 and the bow storage area 23 to and over
the well centres 6 and 7. Well centres 6 and 7 are located within a
pair of rails 24 and 25 which make up Track 16. Such item skids
which will be required at well-centre comprise: spider skid 37,
diverter skid 38, BOP test stump skid (not shown), a Continuous
Circulation System skid (not shown) and a rotary table skid 33.
[0096] Track 17 is used mainly as an access route to get specific
item skids close to the well-centres 6 and 7, wherein the specific
item skids will generally remain on the skids on Track 17 while the
item is operated, such as: a pipe tail handler skid 30; an iron
roughneck skid (not shown); a casing tong skid (not shown); a crane
skid 36.
[0097] Track 18 and 19 are used to route the item skids to a skid
elevator 41. The skid elevator 41 lifts and lowers item skids
between the rig floor 2 and a workshop floor (not shown). Items and
item skids to be repaired and maintained will be moved along the
tracks 18 and 19 to the skid elevator 41 and lowered to the
workshop level which has its own network of rails 43 to move the
item skids to an area of the workshop floor 42 suitable for
repairing and maintaining that particular item skid.
[0098] Cameras 26, 26a, 28, 28a, 29, 34' and 34a are placed in rig
structures at a height suitable to obtain a view of the network of
rails 10. Camera 28 is arranged between derricks 4 and 5 at a
height of preferably five to sixty metres, advantageously, ten to
thirty metres above rig floor towards the top of the derrick
height.
[0099] A spider skid 37 for moving a spider is shown in FIGS. 3 to
5B. The spider skid 37 has: a base 45 for supporting a spider 67;
rail engaging shoes 46; a self-propelling propulsion system 50; a
parking system 55; automatic hook-up system 60 for power and
communication; and automatic on-board control system 70.
[0100] Each of the skids 30 to 38 and any other skid disclosed
herein preferably has a base for supporting an item; rail engaging
shoes; a self-propelling propulsion system; a parking system;
automatic hook-up system for power and communication; an electronic
data gathering system; and automatic control system.
[0101] In use, the spider skid 37 is provided with a flow of
hydraulic fluid to the propulsion system 50 controlled by the
on-board control system 70 to propel the skid. The propulsion
system 50 can operate in a pull or push mode and in a first
direction or a perpendicular second direction. The propulsion
system 50 has a rail gripping foot 51 and a cycling leg 52. The
on-board control system controls a flow of hydraulic fluid to
selectively actuate the rail gripping foot 51 and the cycling leg
52 to push or pull the skid along the rail. The spider skid 37 can
travel at a speed of between 0.3 and 3 m/min or faster.
[0102] The spider skid 37 has a parking system 55. When the spider
skid 37 is close to a predetermined parking spot, a locating pin 56
of a locating pin mechanism 57 on an underside of the square base
plate 66 is activated by master control system 100, which lowers
the locating pin 56 on a pin ram 58, as shown in FIGS. 5A and 5B.
The locating pin 56 is now resiliently biased downwardly against
the rig floor 2 by a resilient means, such as a spring 59. The
spider skid 37 continues under its self-propulsion until the
locating pin 56 passes over a locating hole 2' at which point the
spring 59 biases the locating pin 56 into the locating hole 2'. The
control system 70 ceases the flow of hydraulic fluid to the
propulsion system 55, which stops the spider skid 37 from further
movement. The rail gripping foot 51 is actuated to grip the rail 10
to act as a hand brake. Alternatively or additionally, the parking
system 50 may also act as a hand brake to inhibit the spider skid
37 from moving.
[0103] The master control computer system may be located on the
drilling ship 1 and preferably on a dog house skid 31.
Alternatively or additionally, the master control computer system
100 is located in a control room (not shown) at a distance from the
drilling ship 1, such as on land.
[0104] The automatic hook-up system 60 has a combined hydraulic
fluid supply hose and communication lines 61 provided between the
rig floor 2 and the spider skid 37. Combined hydraulic hook-up and
communication line hook-up points 62 (only four of many are shown
in FIG. 2) are provided in the rig floor 2 between the rails and
approximately 2.8 metres behind each locating hole 2'. Combined
hydraulic hook-up and communication line hook-up points 62 is
connected to a pressurised hydraulic fluid supply (not shown). A
pressurised hydraulic supply is a common feature of all drilling
rigs and drill ships. A hook-up connector mechanism 60 has
connector block 64 comprising a hydraulic connector and a
communication line connector which is arranged beneath a small
self-powered ram 63 to plug the connector block 64 into the
combined hydraulic hook-up and communication line hook-up points 62
The combined hydraulic fluid supply hose and communication lines 61
are fixedly connected to a top of the connector block 64 and wound
around a self-powered reel 65 which has a rewind mechanism (not
shown).
[0105] Before the spider 67 is needed, a command is sent to
operatives in the workshop to prepare the spider skid 37. The
spider 67 is placed on the spider skid 37 in the workshop and
travels up on the skid elevator 41, along tracks 13 and parked in
the buffer storage area 40.
[0106] Referring to FIGS. 5A and 5B, an information package is
collated by the on-board information gathering computer 70. A
parking RFID tag reader 71 arranged on the underside of base plate
45 adjacent the parking mechanism 55. The RFID tag reader 71 is
activated by the on-board information gathering computer 70 to read
parking spot information from RFID tag 72 in the rig floor 2. The
RFID tag 72 reader sends a parking spot information package, such
as location and a reference number to the on-board information
gathering computer 70. A spider RFID tag reader 75 is activated by
the on-board information gathering computer 70 to read spider
information from RFID tag 76. If there is no RFID tag 76 to read,
then an on-board information package is sent to the on-board
information gathering computer 70 indicating that no spider 67 is
aboard the spider skid 37. A further weight sensor arranged on the
base plate 45 and linked to the on-board information gathering
computer 70 may be used to check this is the case. If the RFID tag
reader 70 is able to read the RFID tag 76, the information relating
to the spider 67 is sent to the on-board information gathering
computer 70 as a spider information package. Such spider
information package may include data about the external dimensions,
type of pipe it is suitable for use with, size, and any faults it
may have or have had and subsequent rectifications. An orientation
information package such as orientation of the skid may also be
obtained by the on-board information gathering computer 70 from an
orientation sensor (not shown). A storage memory, such as RAM or
EPROM (not shown) is also arranged on the spider skid 37 containing
a spider skid information package, which contains information such
as a reference number and a description stating that it is a spider
skid. The spider skid information package, orientation information
package, spider information package, on-board information package,
and parking spot information are collated into a skid information
package by the on-board information gathering computer 70 and sent
to the master control computer system 100.
[0107] The master control system 100 is provided with a
pre-programmed arrangement for setting a spider at well centre. The
master control system 100 also has skid information packages from
every skid on the network of rails 10.
[0108] Referring to FIGS. 1 and 2, the camera 26a captures a top
plan view parking image of the crane skid 36 and any other item
skid in the parking area 40. The parking image is sent to the
master computer control system 100. A parking sub-image of the
crane skid 36 is identified and analysed. The parking sub-image
contains a top plan view of the crane skid 36. A reference crane
skid plan view in a stowed position, such as the view shown in FIG.
6A, is stored on the master computer control system 100. The top
plan view of the crane skid of the parking sub image is compared to
the reference crane skid plan view. If the top plan view of the
crane skid of the parking sub-image is significantly different to
the reference crane skid plan view, the master computer control
system 100 sends a signal to the crane skid 37 disallowing movement
along the network of rails 10. A further signal is sent to an
operative in accordance with a health check system, as set out
below. If the top plan view of the crane skid of the parking
sub-image is substantially the same as the reference crane skid
plan view, the master computer control system 100 sends a signal to
the crane skid 37 allowing movement along the network of rails 10
to its destination at parking spot on track 17. Thus the above
described steps check the health of the crane skid to enable travel
along the network of rails 10.
[0109] In order to assess if the top plan view of the crane skid 37
of the parking sub-image is substantially the same as or
significantly different from the reference crane skid plan view,
the master computer control system 100 analyses certain features: a
colour contrast about an outline of the skid against the rig floor;
a colour contrast about features on the base plate of the skid and
the item thereon; depth measurement using a range imaging camera to
identify a feature such as a jib to assess if the jib is up or
down, by measuring the difference between a depth measurement to
the skid base or rig floor and a depth to the end of the jib, taken
from a camera high up in a rig structure above the crane skid. The
depth measurement for the jib 81 in the lowered and raised
positions are preprogrammed into a memory storage area of the the
master computer control system 100.
[0110] Preferably, the skids are of a contrasting colour to the rig
floor. Advantageously, the rig floor 2 is of a predetermined colour
and is consistent thereacross.
[0111] The master control system 100 automatically sends the spider
skid 37 to its destination when required. For instance, the driller
presses an "install drill pipe spider in first well centre" button
on a visual touch screen interface 100' of the master control
system 100 from the dog house skid 31. The destination will be on
track 16 at one of the well-centres 6 or 7, in this case
well-centre 6. The master control computer system 100 controls the
spider skid 37 to withdraw locating pin 56 from locating hole 2'
and then activate the on-board control system 70 to control the
propulsion system 50, so that the spider skid 37 can move to its
destination. From the storage area 40, the spider skid 37 propels
itself to track 16 to a predetermined parking spot 16' next to well
centre 6. Simultaneously, the crane skid 36 (shown in FIGS. 6 to 8)
is sent from buffer storage area 40 to a predetermined parking spot
17' on track 17 close to well centre 6. The crane skid 36 has the
same self-propelling system, parking system, automatic hook-up
system and automatic control system as described with reference to
the spider skid 37. It should be noted that the reel of the
automatic hook-up system is not shown in FIGS. 6 to 8 for clarity.
The crane skid 36 has a crane 80 with a jib 81 in a retracted
position and a travelling block 82 in a retracted and stowed
position for transport along the network of rails 10. The crane
skid 36 is parked on track 17 at the predetermined parking spot 17'
using a parking mechanism (not shown), which is identical to the
parking mechanism 55 shown and described with reference to the
spider skid 37. The crane 80 on crane skid 36 is then operated from
a remote location, such as from the dog house skid 31, using
fly-by-wire control system (not shown) to activate hydraulic valves
in the crane 80, or can be operated in automatic mode by the master
control computer system 100. The computer system 100 knows the
absolute location of the crane skid 36 and the spider skid 37 from
the crane information package sent from the crane skid's on-board
control system. In automatic mode, the jib 81 is raised using ram
83 and extended using ram 84 over the spider 67 in the spider skid
37. A hook 85 is lowered on line 86 over the spider 67 and under a
hook receiver of the spider (not shown). The hook 85 is raised on
line 86, lifting spider 67. The crane 80 is rotated on rotating
table 87 and lowered into well-centre 6. The crane 80 thus has an
unsafe zone 99 about the crane skid 36 in which it is not safe for
rig hands to be during use. This unsafe zone 99 may be the expected
area of use defined by an angle defined by the jib 81 over the
spider 67 traversing to the well-centre plus an additional angle in
which the jib is likely to move during this operation and the
expected length of extension of the jib 81, as well as topple zone
in case outriggers are not activated properly or if the item to be
lifted is too heavy for the crane. An unsafe zone further includes
an angle in a vertical plane defined by the rig floor 2 and the jib
81 when lifted on ram 83 to an expected working angle. Thus the
unsafe zone may be two dimensional and preferably three
dimensional.
[0112] Alternatively, the unsafe zone may be defined by the entire
360 degrees on movement in which the crane 80 can traverse in top
plan view, maximum length of the jib 81 when fully extended and an
angle formed by the jib and the rig floor when ram 83 is fully
extended and a further safety margin for hook swing on line 86.
However, this may be an unnecessarily large unsafe zone.
[0113] The crane skid 36 has an expected stowed plan view as shown
in FIG. 6 for transportation along network of rails 10 having an
unsafe zone 88 marked in dashed lines.
[0114] The crane skid 36 also has an expected unsafe zone 89' when
moving along track 17, shown as a northerly direction. The
additional area is an area located in the direction of travel of
the crane skid 36 and is of sufficient length from the crane skid
36 to allow the skid to be stopped from the maximum speed of the
skid as well as time for the obstruction to be observed and acted
on.
[0115] During the spider skid's journey from the storage area 40 to
the parking spot 16' on track 16 the skids on the network of rails
10 are monitored using the cameras 26 and 28. The cameras 26 and 28
capture a series of master images in real time, preferably at a
frame rate of once per second and each master image is sent to the
master computer control system 100 for analysis. The master images
are used in four ways: to continuously monitor the health of the
skid; to mitigate collisions; to mitigate accidents between skids
and rig hands; and to mitigate accidents between tools and rig
hands.
[0116] The continuous monitoring of the health of the skid is
carried out in the same way as the health of the skid was assessed
in the storage area, and as shown in and described herein with
reference to FIG. 23.
[0117] The mitigation of collisions is carried out using the master
computer control system 100 using steps shown in FIGS. 9 and 10.
Referring to FIG. 9, the master computer control system 100 already
has information from the skids 30 to 38 in the form of item skid
information data packages which are continuously updated,
preferably at a rate of at least one update per minute and
preferably one to fifty updates per second. The master computer
control system 100 controls the item skids 30 to 38 by issuing
commands to each item skid according to predetermined and
preprogrammed set of sequences to complete a particular task, such
as an "install drill pipe spider in first well centre" task as set
out above with reference to FIG. 6. If the preprogrammed set of
sequences is followed, a collision should not occur. A datum
location for each item skid 30 to 38 for those which are travelling
along the tracks is estimated by knowing the departure time from a
parking spot, the route and the speed at which the item skid is
travelling e.g. 1 metre per minute. Location and orientation
information for each item skid is compiled as datum location and
orientation information and/or mapped by the master computer
control system 100 to create a datum map. The items on the item
skids 30 to 38 are in a stowed position and a stowed unsafe zone is
predefined for each item skid.
[0118] The series of master images captured in real time are used
to check that the skids 30 to 38 are all in their correct parking
spots or travelling on their correct routes at an expected point
therealong as identified by the skid information data packets and
the preprogrammed set of sequences. The master control computer
system 100 creates sub-images for each skid 30 to 38 to identify
each skid. Once a sub-image has been created, the item skid is
identified using the technique described with respect to the
hierarchical structure as set out above, using colour contrast data
about an outline of the item skid and/or item on the skid and/or
range data for mapping the entire shape of the item skid and
comparing results with a preloaded reference list of item
skids.
[0119] Once each item skid has been identified, it is located using
range information from the camera in combination with directional
information and compared to the datum location and orientation
information and preprogrammed set of sequences. Alternatively or
additionally the master image is compared to the datum map to
assess if the item skids are out of place.
[0120] If the item skids 30 to 38 are all in the anticipated
positions, sequence "A" is carried out by the master computer
control system 100, which simply allows the task to continue.
[0121] If one or more of the item skids 30 to 38 is out of place
compared to the datum location and orientation and preprogrammed
set of sequences, a sequence "B" is followed which comprises an
alert sent to the driller or tool pusher in the dog house 31 and/or
an operative according to a set of health check and hierarchical
rules as set out below with reference to FIG. 25.
[0122] Furthermore, sequence "B" also includes the master control
computer system 100 identifying any other item skid within the
predefined short stowed unsafe zone, from with the one or more item
skids 30 to 38 identified as being in a different place, and if
collision is likely with the one or more item skids 30 to 38 in a
different place to send a command to the other item skid to stop or
take a different predetermined route.
[0123] Furthermore, as sown in FIG. 10, a collision mitigation
system also comprises the master control computer system 100
identifying the stowed unsafe zone for each of the item skids 30 to
38. The skid information package includes an item information
package which has information about the type of item skid, such as
crane skid and if the item is in use. If the item, such as a crane
is in use, an in-use unsafe zone is defined. This is defined in
default as the maximum range of movement of the jib plus a further
safety margin. However, the in-use unsafe zone is defined to a
reduced size with information from a particular task, such as the
task described with reference to FIG. 6, wherein the zone is
reduced to approximately eight metres from the centre of the crane
skid in a seventy-five degree zone in a horizontal plane and
seventy-five degrees in a vertical plane and a small area about the
base of the crane skid 36.
[0124] A system for mitigating accidents between item skids or
tools and rig hands is also provided. With reference to FIG. 11,
the series of master images from cameras 26 and 28 are analysed by
the master control computer system 100 to identify if any rig hands
appear in the master image and then identifies the location of the
rig hand on the rig floor 2. The master control computer system 100
has a set of preprogrammed unsafe zones in which rig hands are not
allowed, and a set of default unsafe zones for each item skid 30 to
38, and an in use unsafe zone for each item skid when used in a
predefined task, such as a the in-use unsafe zone described above
with reference to the crane skid 36 during a spider installation
operation, or in front of an item skid travelling along a track of
the network of rail 10. If the rig hand is within the in-use unsafe
zone, the master control computer system 100 sends a command to the
item skid to cease operation. In this case, if the rig hand is
within the in-use unsafe zone of the crane skid 36, the master
control computer system 100 sends a command to the crane skid 36 to
cease operation.
[0125] The dog house skid 31 shown in FIG. 1 comprises a cabin 90,
arranged on a skid 90' incorporating the same self-propelling
system, parking system, automatic hook-up system and automatic
control system as herein described with reference to spider skid
37. A rotating base such as a turntable, is arranged between the
skid 90' and the cabin 90 to allow the cabin 90 to rotate relative
to the skid 90' to facilitate the driller and tool pusher to obtain
the best view of the well centres 6 and 7. A parking spot and route
is preprogrammed into a memory of the master control computer
system 100 for each of the preprogrammed layouts for drilling
casing, riser installation, intervention etc. In this case, a
stowed unsafe zone is preprogrammed in the item skid information
package or the master control computer system 100, which defines a
circle in which the dog house can rotate thereabout. An in-use
unsafe zone is preprogrammed into a memory of the master control
computer system 100 for each layout.
[0126] A diverter skid 38 is shown in FIGS. 12 and 13 having a
diverter 91 thereon. The diverter skid 38 is provided with the same
self-propelling system, parking system, automatic hook-up system
and automatic control system described with reference to the spider
skid 37. The diverter skid 38 is thus generally similar to the
spider skid 37, save for the following differences. The diverter
skid has a generally planar base plate 92 and a lifting arm
mechanism 93. A ram 94 and 94' is pivotally arranged on opposing
sides of the base plate 92 and elbows of rigid kinked arms 93 and
93'. A powered crown block 95 is hung from a top bar 93'' linking
tops of the rigid kinked arms 94 and 94'. A wireline 96 runs
between the powered crown block 95 and a small travelling block 97
having a connector 98. In this case, a stowed unsafe zone is simply
an area defined by the base 92 of the diverted skid 38 plus a small
margin.
[0127] In use, the master control system 100 automatically sends
the diverter skid 38 to its destination when required. For
instance, the driller can press an "install diverter in first well
centre" button at a visual interface (not shown) of the master
control system from the dog house skid 31. The destination will be
on track 16 at one of the well-centres 6 or 7. The master control
computer system 100 controls the diverter skid 38 to activate the
parking system to withdraw a locating pin from locating hole 2' and
then activate the on-board control system to control the propulsion
system, so that the diverter skid 38 can move to its destination.
From the storage area 40, the diverter skid 38 propels itself to
track 16 to a predetermined parking spot next to well centre. The
lifting arm mechanism 93 is initially arranged in a first position
identified in ghost lines in FIG. 14, with rams 94 and 94' in a
substantially upright position and with the connector 98 connected
to a lifting point (not shown) on the diverter 91. The master
control computer system 100: activates the powered crown block 95
to lift the diverter 91 clear of the base 131; extends hydraulic
rams 94 and 94' to shift the diverter over well centre 6; to
activate the powered crown block 144 to lower the diverter 91 on to
well centre. Alternatively, the lifting arm mechanism 93 is
operated from a remote location, such as from the dog house skid
31, using fly-by-wire control system (not shown) to activate
hydraulic valves (not shown) in the lifting arm mechanism 93.
Hydraulic power and communication lines for the lifting arm
mechanism 94 and 94' is provided through an auxiliary line (not
shown) on the diverter skid 38, which branches from the combined
hydraulic fluid supply hose and communication lines 61. Thus an
additional hook-up is not required. An in-use unsafe zone 90' is
predefined for the task and shown with dashed lines in FIGS. 12 and
13.
[0128] Bare skids may be provided with a simple square planar base
plate to move other items around the rig floor 2. Two or more bare
skids can operate in unison one behind the other in order to move
long or large items. A stowed unsafe zone is programmed in manually
for each item or chosen from a predefined list preprogrammed into
the master control computer system 100. Alternatively or
additionally, a safety image of the item on the bare skids is
obtained. The safety image is processed by the master control
computer system 100 and an algorithm used to estimate an area about
the bare skids for a safety zone.
[0129] The pipe tail handler skid 30 shown in FIGS. 1 and 2, is
provided with the same self-propelling system, parking system,
automatic hook-up system and automatic control system described
with reference to the spider skid 37, although may have the manual
hook-up system described with reference to the BOP test stump skid
39. The pipe tail handler skid 30 is thus generally similar to the
spider skid 37, save for the following differences. The base 167 is
substantially planar with a vertical rigid column 168 on which is
mounted an articulated pipe handler arm 166 having a pipe gripper
169. The pipe handler arm 166 and pipe gripper 169 are
hydraulically actuated and controlled from the master control
computer system 100. Hydraulic power and communication lines for
the pipe handling arm 166 is provided through an auxiliary line
(not shown) on the pipe tail handler skid 30, which branches from
the combined hydraulic fluid supply hose and communication lines
100. Thus an additional hook-up is not required. A stowed unsafe
zone is defined as the area of the base plate and with the pipe
handler arm 166 in a retracted position and the height of the
column, plus a small additional margin. A default in-use unsafe
zone includes an extension of the pipe handler arm 166 and a swept
area in which the pipe handler arm 166 can move and may also
include a topple area. A predefined task would be, for example in
drilling and tripping-in in controlling a tail end of a stand of
drill pipe to facilitate stabbing into a string of drill pipe in
the well at well centre 6 and 7.
[0130] The riser handling arm skids 32 shown in FIG. 1 are each
provided with the same self-propelling system, parking system,
automatic hook-up system and automatic control system described
with reference to the spider skid 37. The base 190 is formed in a
structural X-shape lying in a horizontal plane with a planar square
central portion 191 on which is a rotatably mounted horizontal
telescopic riser handling arm 193 having a riser guide 194. The
extendible riser handling arm 193 is hydraulically actuated and
controlled from the master control computer system 100. Hydraulic
power and communication lines for the extendible riser handling arm
193 is provided through an auxiliary line (not shown) on the riser
handling arm skid 32, which branches from the combined hydraulic
fluid supply hose and communication lines 100. Thus an additional
hook-up is not required. A stowed unsafe zone is defined as the
area of the base plate and with the riser handling arm 193 in a
retracted position and the height of the column, plus a small
additional margin. A default in-use unsafe zone includes an
extension of the riser handling arm 193 and a swept area in which
the riser handling arm 193 can move. A predefined task would be,
for example in building and lowering a riser in controlling a tail
end of a section of riser when being moved from a store to well
centre 6 and 7.
[0131] The coiled tubing skid 34 shown in FIG. 1, is provided with
the same self-propelling system, parking system, automatic hook-up
system and automatic control system described with reference to the
spider skid 37. The base 195 is generally planar, with a drum frame
196 rotatable mounted thereon. The drum frame has a drum 197
mounted therein, with a drum having a horizontal axis. The drum
frame 196 is rotatably mounted on the planar base 195, such that
the drum frame 196 can rotate about a vertical axis to allow coiled
tubing 198 on the drum 197 to be played out perpendicularly to the
axis of the drum, no matter where the coiled tubing skid is located
on the network of rails 10. The drum 197 has a drive system (not
shown) to help winding and rewinding. The drive system may be
hydraulically actuated and controlled from the master control
computer system 100. Hydraulic power and communication lines for
the drive system is provided through an auxiliary line (not shown)
on the coiled tubing skid 34, which branches from the combined
hydraulic fluid supply hose and communication lines 100. Thus an
additional hook-up is not required. A stowed unsafe zone is defined
as the area in plan of the reel 197 and the height thereof, plus a
small additional margin. A default in-use unsafe zone includes the
area in plan of the reel when rotated, thus defining a cylindrical
unsafe zone and an additional area in which the coiled tubing will
be played out, such as between the coiled tubing skid and well
centre. A predefined task would be, for example in a well
intervention operation with a coiled tubing investor head, shown in
FIG. 1 at well centre 6.
[0132] The network of rails 10 comprises track 11 to 19 in a layout
which will be suitable for a rig floor on a dual derrick drill
ship. A layout for other types of rigs such as a single derrick
drill ship will be very similar although will have fewer track. A
layout for an FPSO having a double derrick will be the same or very
similar. A layout for offshore platform having a double derrick,
SPAR platform, SWATH sea star platform and tensioned leg platform
will be the same or very similar. Although, a skilled man will be
able to draw up suitable modified layout for each type of rig. The
network of rails may be simplified for a land rig, which generally
has a much smaller rig floor.
[0133] It is envisaged that other items could be conveyed and used
whilst remaining on the skids of the invention, such as an iron
roughneck and continuous circulation tool.
[0134] FIGS. 14 to 16 show schematically a land drilling rig
generally identified by reference numeral 200. The drilling rig 200
comprises a derrick 110 extending upwards from a rig floor 111. A
drilling hoist comprising a travelling block and a swivel and hook
assembly is mounted at the upper part of the derrick, but is not
shown in the drawings for clarity. A top drive unit, is mounted on
a carriage so as to be displaced along a vertically extending
track, is suspended by the hoist in a manner known per se, which
are not shown in the drawings for clarity. The drilling hoist and
the top drive unit suspended thereby are substantially aligned with
a drilling opening 118, known as the well centre, defined in the
rig floor 111, and the top drive unit may be brought into rotary
driving engagement with the upper end of a drill string 119
extending through the drilling opening 118.
[0135] Two assembling or preparation openings 120 and 121, known as
mouseholes, are defined in the rig floor 111 located in close
proximity to the well-centre 118. A pipe handling apparatus for
loading drill pipe and preparing stands of drill pipe is generally
identified by reference numeral 122. The pipe handling apparatus
122 comprises a vertically extending frame tower 123 and a
slideable carriage 124, which may be referred to as a dolly, to
which is arranged an elevator 101. The pipe handling apparatus is
provided in close proximity to the mouseholes 120 and 121 and an
opening in the side of the derrick 110 known as a V-door 125
facilitates access to areas off the drill floor 111, including
access to an access ramp 127, known as a slide, and an area for
storing pipes and an access way for use in transferring the pipes
from the storage areas to the platform 111, known as a catwalk
128.
[0136] The drill floor 111 further comprises finger boards 129 and
130 for setting back stands of drill pipe or bottom hole assembly
parts in a vertical position defining a setback area. A pipe
handling arm 131 for loading and unloading the storage areas 129
and 130 has a rotatable and extendable gripping device 132 mounted
generally in the setback area between the two finger boards 129 and
130 and advantageously in the upper portion of the derrick and
within the structure of the derrick 110 to provide for moving
stands of pipe or joints of pipe between the well-centre, stand
building mouseholes 120 and 121 and/or finger boards 129 and
130.
[0137] The rig floor further carries drawworks associated with the
drilling hoist. A drillers' cabin C, known as a dog house is
provided for the operator or driller to operate the pipe handling
apparatus and drilling operations.
[0138] The pipe handling apparatus 122 comprises a tower 123, which
is slightly taller than three joints of drill pipe. A joint of
drill pipe is generally about 9.1 m (30 feet) long and so the tower
123 would be at least 30 metres tall for handling stands of three
joints of pipe. The two joints of drill pipe are connected by
spinning and torquing device 150, known as an iron roughneck, which
is shown in more detail in FIGS. 21 and 22
[0139] The pipe handling apparatus 122 also comprises a carriage
124 having an arm 133 mounted thereon. The carriage is arranged on
wheels 134 which facilitate movement of the carriage up and down
the tower 123. The carriage 124 does not rotate with respect to the
tower 123.
[0140] The tower 123 is mounted in lower 136 and upper 137 rotary
platforms, so that the tower 123 can rotate about its longitudinal
axis. The rotary platforms are driven by a hydraulic, pneumatic or
electric motor and controlled from the operator or driller's cabin
C. The rotary tables are arranged on bearings (not shown), and the
tower could be rotated manually.
[0141] A wire 135 having eyes spliced into the wire at each end are
connected at one end to the shackle 8 of the elevator 101 and
another wire 135 of substantially the same type is attached to
shackle 9 of the elevator 101. The other ends of the wires 135 are
attached to a yoke 138. A further wire may be attached to shackle
10 to control the orientation of the single joint elevator 101 or
to help take the weight of the elevator and the pipe therein and
may be attached to the yoke 138. The yoke 138 is attached to the
end of a wireline 135 which passes between pulley wheels 141
arranged at a distal end of the arm 133 and over a pulley 139 at
the top of the tower 123 and down through the frame structure of
the tower to a winch (not shown). The winch (not shown) may be
controlled by the operator from the driller's cabin C.
[0142] A master computer control system 250 is located in the dog
house C and is provided with a user interface, such as a touch
screen 251. Three rig hand safety cameras 252, 253 and 254 are
fixed to lattice members 255 of the derrick 110 at a height of
approximately fifteen metres. The cameras are arranged to have a
field of view of the entire rig floor 111 with as little
obstruction as possible. The field of view of each camera 252, 253
and 254 overlap.
[0143] In use, a joint of drill pipe is placed on the catwalk 128.
Elevator 101 fitted on to the joint. The winch (not shown) is
operated to wind the wireline 140 in, pulling the elevator 1 and
the drill pipe 40 engaged in therein up the ramp 128, as shown in
FIG. 10. The yoke 138 engages with the arm 133 near the guide
rollers 141, pulling the arm 133 and the carriage 124 up the tower
123. Once the joint of drill pipe 40 is clear of the platform 111,
as shown in FIG. 11, the winch is stopped and the tower 123 is
rotated on rotary tables 136 and 137 by approximately 120 degrees,
so that the joint of drill pipe 40 is now in line with the first
mousehole 120. The winch is operated to unwind the wireline 140 to
lower the carriage 124 and the joint of drill pipe 40 into the
mousehole 120. The single joint elevator 101 is disconnected, the
tower 122 rotated and then tumbles down to the catwalk 128 where a
second joint of drill pipe 142 has been placed in the same fashion
as the first. This is repeated with a second joint, which is
connected to the first at the mouse hole with an iron roughneck
150. The iron roughneck 150 is retraced on arm 152 and swung about
pillar 151 to a storage position, or to be used at the well-centre
118. Once a stand 142 of two or three joints has been constructed.
The winch is operated to wind the wireline 140 to lift the elevator
101 and the stand up guided by the carriage 124 out of the first
mousehole 120. The tower 123 may be rotated towards a raised
platform situated at the top of the fingerboards 129 and 130. A
pipe handling arm 131, such as the one sold by BJ Varco under the
trade name VCR, grabs the triple. The derrickman on the stabbing
board removes the safety locking pin 55 from the elevator 101 and
pulls back on the handle 58 to release the elevator 101.
Alternatively, the elevator 101 may be operated remotely. The iron
roughneck 150 may be moved into alignment with the well-centre for
"just-in-time" stand building operations and moved on extendible
arm 151 into engagement with the drill pipes to perfect a
connection with the drill string.
[0144] Drilling may be simultaneously conducted at the well-centre
118 whilst preparation of a stand of pipe or a single is
transferred from the catwalk 128 or ramp 127 to the well-centre 118
and/or fingerboard, as described herein.
[0145] The cameras 252, 253 and 254 capture a master image at a
rate of approximately ten master images per second and are sent
electronically to the master control computer system 250 for
processing in real time.
[0146] The cameras 252, 253 and 254 are preferably digital range
imaging cameras, but may be analogue, the image converted to a
digital file and transportation to the master control computer
system 250. The cameras 252, 253 and 254 may be of the
charge-coupled device (CCD) or complementary metal-oxide
semiconductor (CMOS) type.
[0147] The master control computer system 250 has a memory
preloaded with instructions to recognise tools and equipment on the
rig floor 111. This is carried out in an identification procedure
in a set-up process, which comprises taking item images of the
tools and equipment, preferably with the cameras 252, 253 and 254
in the position of use in the derrick 110. The tools and equipment
may be items such as an iron roughneck. Contrasts in colour, such
as an outline of the tool is mapped and defined by a user as for
example an iron roughneck to produce a named digital tool map. The
digital tool map is then stored in an accessible memory.
[0148] The set up procedure also includes establishing an unsafe
zone for each tool. A default unsafe zone is mapped by commanding
the tool to carry out a full range of movement whilst capturing a
series of images with the cameras 252, 253 and 254. An in-use
unsafe zone is mapped by commanding a range of movements used for a
specific task whilst capturing a series of images with the cameras
252, 253 and 254. For example, the iron roughneck 150 is movably
arranged on a retractable arm 152 relative to a pillar 151 and can
also swing thereabouts between mouse holes 120, 121 and well centre
118 when tripping-in and stand building. The iron rough neck 150 is
then used whilst the cameras 252, 253 and 254 capture a series of
images to be analysed by the master control computer system 250 to
define an in-use unsafe zone 150' about the tool. This set up
procedure may be carried out for each tool for each task.
[0149] The master image captured by cameras 252, 253 and 254 is
scanned by the master control computer system 250 for items which
have the same features as identified in the identification
procedure. Once identified, the item is mapped on to a digital map
of the rig floor 111. In this case, the iron roughneck is mapped on
to the digital map, which may be displayed on visual interface 251.
The pre-established unsafe zone is also mapped on to the digital
map and preferably displayed on the visual interface 251.
[0150] The master control computer system 250 is also preloaded
with a rig hand recognition system, which may comprise a set up
procedure for recognising the outline of a rig hand 260 from above,
using colour contrast. The master image is analysed by the master
control computer system 250 in real time to look for rig hands 260
in the master image. If a rig hand 260 is present, a location point
will be mapped on to the digital map and preferably displayed on
the visual interface 251.
[0151] If the location point of the rig hand is within an in-use
unsafe zone of a tool, such as the iron roughneck 251, a command
will be sent from the the master control computer system 250 to
instruct the tool to shut down, ceasing operation and alert the
driller on the visual interface 251.
[0152] Another example of a tool is the pipe handling apparatus 122
which has a cylindrical unsafe zone 122' about the tower 123. Yet
another example of a tool is the pipe handling arm 131 which has a
cylindrical unsafe zone about well-centre, the mouse holes and
setback area.
[0153] FIG. 17B shows part of a drilling rig generally similar to
the drilling rig shown in FIG. 15 with like reference numerals
referring to like parts. The drilling rig also comprises three rig
hand safety apparatuses 300, 301 and 302 arranged above the rig
floor 111 on the derrick 110. Each of the rig hand safety
apparatuses 300, 301 and 302 is substantially the same as the
other. Optionally, each rig hand safety apparatus 300, 301 and 302
is located approximately 5 m to 8 m above the rig floor 111 but may
be arranged between 1.5 m and 12 m above the rig floor 111. Each
rig hand safety apparatus 300, 301 and 302 is directed towards the
rig floor 111 at a slight angle thereto and directed away from each
other so that substantially all of the rig floor 111 is in within
the combined field of view of the rig hand safety apparatus 300,
301 and 302. The field of view of each may overlap.
[0154] FIG. 17C shows a rig hand safety apparatus 300 incorporating
a rig hand safety camera 252. The rig hand safety apparatus 300 has
an explosion proof housing 303 having a window 304. The window 304
is provided with a wiper 305 having a wiper motor 306 and rain
sensor 307 for keeping the window 304 clean, free from rain spots
and dirt. The camera 252 is located within the x-proof housing 303
and directed downwards towards the rig floor 111. A thermal imaging
camera 304 is also located within the x-proof housing 303.
[0155] A light source 308 is also enclosed in the housing 303 and
directed in concert with the camera 252 to illuminate the field of
view 309 of the camera 252. Preferably, the light source is
powerful enough to flood light on to the rig floor 111 with a light
intensity of preferably at least 350 LUX at the rig floor 111. Such
light intensity is sufficient to allow the reflected light to be
detected by the camera 252. The light source optionally emits light
over a range of wavelengths which optionally covers the range of
wavelengths detectable by the camera.
[0156] The camera 252 optionally detects a range of wavelengths
covering visible light and optionally infrared. The rig hands 320
optionally have markers on them which are receptive to visible
and/or infrared light. For example, a reflector 310-313 such as a
reflective tape supplied by 3M corporation under the Scotchlite.TM.
brand reflective material type 3150A SOLAS Grade Pressure Sensitive
Adhesive Film Silver in white or blue, which facilitates reflection
of infrared light. The reflective material 310, 313 may be adhered
to the helmet 315 or shoes 316 of the rig hand. The reflective
material may be of a distinctive shape to distinguish it from other
shapes and reflective surfaces found on a rig floor 111. The
reflective material 311, 312 may be sewn, adhered or form part of
overalls 317 of the rig hand, such as a rectangular strip across
the back or over shoulders.
[0157] The cameras 250, 304 captures an image of the rig floor 111
and everything thereon in real time, optionally at a refresh rate
of once every second. Each image is sent to the control system CS
wherein an algorithm is used to analyse the image. The image is
analysed by the computer system CS.
[0158] The heat sensing camera 304 identifies one or the other of
inanimate objects and rig hands to differentiate the two. The
master computer control system CS comprises an algorithm for
filtering out parts of the obtained images which are not likely to
be rig hands. The structure of the drilling rig including lattice
members 255 have a heat signature which is very different to that
of a rig hand 320 and thus the master computer control system CS
filters out large parts or all of the image. Certain movable
machines, such as an iron roughneck 150, has a heat signature which
is very different to that of a rig hand 320 and thus the master
computer control system filters out large parts or all of the
image. Furthermore, certain known items are static and always
present of a rig floor, such as a derrick 110 and tower 139.
Details of these known items may be contained in a known items
database. The master computer control system CS may be provided
with an additional algorithm to filter out parts of the image of
those details held in the known items database. The parts of the
image that are left are then analysed using further algorithms. The
master computer control system may further comprise a database of
known heat signature profiles for machines or any other object
likely to be found on a rig floor. The master control computer
system may be provided with an algorithm to compare the obtained
heat signature profiles with those in the database to discount them
from being a rig hand 320.
[0159] Rig hands 320 generally have an identifiable heat pattern
signature. The master computer control system CS is optionally
provided with an algorithm to assess if there is a heat pattern
which is indicative of a rig hand. The master computer control
system CS is also provided with an algorithm to assess the location
of the heat pattern indicative of a rig hand 320 on the rig floor
111.
[0160] Rig hand 320 has certain identifiable signatures which do
not vary considerably from one rig hand 320 to another. Such a
feature is the helmet 315. Another feature is the face 319 of the
rig hand 320. The system uses camera 252 for receiving reflected
light information to assess a signature shape of at least part of
the rig hand 320, such as a helmet 315 or face 319.
[0161] If the two results (light and heat sensing) are positive, it
is highly likely that the master computer control system CS has
identified a rig hand 320. If only one of the light image camera
252 and heat sensing camera 304 identifies a rig hand 320, the
system assumes there is indeed a rig hand 320 in that location. In
this way, the system has more redundancy and less likely to allow
an operation within an unsafe zone to be carried out.
[0162] Referring to FIGS. 17D and 17E an entrance camera unit 340,
341, 342 is located at every entrance point 343, 344 to the rig
floor 111. The drilling rig shown in FIG. 17E, has two sets of
stairs 345, 346 leading up to the rig floor 111 and one door 347 to
dog house C thus there are only are three entrances to the rig
floor 111. Each entrance camera unit 340, 341, 342 is attached to
rig structure 348 and arranged to have a field of view 349 directed
at the rig hand 320. Each entrance camera unit 340, 341, 342 is
substantially the same as the other. Entrance camera unit 340 is
shown in FIG. 17D, which comprises a camera 350 and a light source
351 to illuminate the rig hand 320. The camera 350 captures an
image of the rig hands 320.
[0163] The master computer control system CS is provided with an
algorithm for identifying a common feature of the rig hand 320 such
as helmet 315. In this way, the master computer control system CS
can differentiate a rig hand 320 passing through the entrance 344
from an item passing through the entrance 344. Optionally, the
camera 250 is directed at the rig hand's face, so that the rig
hand's face is in the field of view of the camera 250. The master
computer control system CS is provided with a face recognition
algorithm for identifying the rig hand 320.
[0164] The master computer control system is provided with an
algorithm to keep a tally of rig hands on the rig floor. The tally
may simply be the number of rig hands on the rig floor. Optionally,
the camera located at every entrance to the rig floor has a field
of view directed at the rig hand's head.
[0165] In this way, the tally recorded by the master computer
control system also includes a list of names of rig hands on the
rig floor.
[0166] Optionally, the master computer control system CS also
comprises an algorithm to compare the tally with the number of rig
hands 320 located using the system of the invention on the rig
floor 111. If the numbers are not equal, a further rig hand's
signature is looked for or the tool pusher or driller is alerted.
The master computer control system CS may also be provided with the
number of helmet location devices 330 active on the rig floor 111
as a further check. The helmet location device 330 comprises a
locator and a transmitter for transmitting a location signal of the
helmet 315 back to the master control computer CS.
[0167] Optionally or additionally, each entrance camera unit 340,
341, 342 comprise a thermal imaging camera 352. The thermal imaging
camera 352 sends a thermal image pattern of any object or rig hand
passing through the entrance 343, 344, 347. The thermal image
pattern is sent to the master computer control system CS, which
runs an algorithm to assess if the object or rig hand is a rig hand
320. FIGS. 18 and 19 show a top drive system 410 according to the
present invention with a becket 416. The top drive system 410 has a
swivel body 412 suspended with links 414 from the becket 416. The
becket 416 is connected to a travelling block (not shown). A gear
system 420 is mounted on a spacer plate 422 which is supported by
the swivel body 412. A motor 430 is coupled to the gear system 420.
A brake system 440 connected to the motor 430 is within a bonnet
444 through which extends a gooseneck 446 connected to a kelly hose
407 through which flows drilling fluid. An extension system 498
provides horizontal displacement of the top drive system 410. A
gripping system 401 for selectively gripping tubulars is suspended
from a load collar 470. Links 472 suspend an elevator 500 from the
load collar 470. A counterbalance system (which can hold the weight
of the entire system 410 during stabbing of tubulars) includes load
compensators. A link tilt system 402 provides selective tilting of
the links 472 and thus selective movement and tilting of the
elevator 500 and movement of a tubular or stand of tubular
supported by the elevator 500 to and away from a wellbore
centerline. Bail retainers 475 retain the links 472 on the load
collar 470. Link tilt hydraulic cylinders 476 are interconnected
pivotably between the load collar 470 and arms 422. Each connector
424 is pivotably connected to a lower end of an arm 422 and to a
clamp 426 which is clamped to a link 472. Guards 473 and 490 are on
sides of an access platform 438. The top drive system 410 can be
movably mounted on a beam 499 (or "torque tube"). Horizontal
displacement is provided by the extension system 498 which includes
a torque bushing 98a. The extension system 98 with the top drive
system attached thereto is movable vertically on the beam 482 with
the top drive system attached thereto.
[0168] A health check camera 450 is fixed to a strut of derrick 110
which has a field of vision encompassing a side profile of the top
drive system 410. Thus the health check image preferably includes
the becket 416, goose neck 446, motor 430, gearbox 420, rams, links
472, elevator 500, load collar 470, extension system 498, gripper
401 and guards 473.
[0169] The health check camera 450 captures a health check image of
the side profile of the top drive system 410 and sends the health
check image to the master control computer system 250. More than
one health check camera may be used with overlapping images, which
are collated by the master control computer system into one master
health check image.
[0170] The health check image is captured when the top drive system
is located along track 482 in direct view of the camera 450. The
camera 450 is preferably placed at a point having a field of vision
of the top drive when the top drive system is stationary for a time
which allows a good quality image to be captured, such as where the
top drive is stationary immediately prior to connection to a drill
string, a default rest location or at a top point along the track
where the top drive system changes direction of travel along the
track 482.
[0171] Alternatively, the camera 450 is mounted on a track which
allows the camera to move in concert with the top drive system 450
or is located on an arm extending out from the top drive system
410.
[0172] A reference top drive side view image is stored on the
master computer control system 250. The reference top drive side
view image is preferably taken by the camera 450 from the same
fixed point on the derrick of a previously manually inspected view
to ensure the reference image is of the top drive system 410 in
full working order. The working top drive side view image is
compared to the reference top drive side view image. If the working
top drive side view image is significantly different to the
reference top drive side view image, the master computer control
system 250 sends a signal to a top drive system controller to cease
operations.
[0173] As an additional step or an alternative to the cease
operation command, a signal is sent to an operative in accordance
with a health check system, as set out below. If the reference top
drive side view image is substantially the same as the working top
drive side view image, the master computer control system 250 sends
a signal to the top drive system controller (not shown) allowing
continued operation of the top drive system 410.
[0174] In order to assess if the difference is substantial, the
master control computer system 250 applies a number of algorithms
to the difference such that differences caused simply by mud or
scratched paint are ignored, and that differences, such as a crack,
loose bolt, sheared bolt, deformation of stressed members or
leaking ram are noticed as substantial differences. Using a range
imaging camera an assessment for a loose bolt can be made and size
and depth of crack using absolute distances or relative distance
measurements between entrance to depth of crack and distance
between bolt head and substrate. A colour check is also used to
assess if the difference is substantial, for instance a red-brown
colour would indicate mud, a dull silver would indicate a scratch
and a bright faceted silver would indicate a crack. A contrast
about an outline of the top drive system and parts thereof, such as
bails, links and rams and a change in the outline may indicate
deformation.
[0175] Preferably, various parts of the top drive system are of a
contrasting colours.
[0176] Further health check cameras may be located above, below,
behind, in front and on an opposing side the top drive system.
[0177] Referring to FIG. 20 there is shown an elevator system
comprising an elevator 500 comprising a main body 501, doors 502
and 503, a latch 504 between the two doors 502 and 503. The main
body 501 has opposing ears 504 and 505. A multiplicity of bolts 506
fix respective plates 507. A health check camera 510 is fixed to
the top drive system 400 with a top of the elevator 500 in a field
of view.
[0178] A reference elevator top view image is stored on the master
computer control system 250. The reference elevator top view image
is preferably taken by the camera 450 from the same fixed point on
the top drive system of a manually inspected elevator to ensure the
reference image is of the elevator 500 in full working order. The
working elevator top view image is compared to the reference
elevator top view image. If the working elevator top view image is
significantly different to the reference elevator top view image,
the master computer control system 250 sends a signal to a top
drive system controller to cease operations.
[0179] As an additional step or an alternative to the cease
operation command, a signal is sent to an operative in accordance
with a health check system, as set out below. If the reference
elevator top view image is substantially the same as the working
elevator top view image, the master computer control system 250
sends a signal to the top drive system controller (not shown)
allowing continued operation of the top drive system 410.
[0180] In order to assess if the difference is substantial, the
master control computer system 250 applies a number of algorithms
to the difference such that differences caused simply by mud or
scratched paint are ignored, and that differences, such as a crack,
loose bolt, sheared bolt or deformation of stressed members are
noticed as substantial differences. Using a range imaging camera an
assessment for a loose bolt can be made and size and depth of crack
using absolute distances or relative distance measurements between
entrance to depth of crack and distance between bolt head and
substrate. A colour check is also used to assess if the difference
is substantial, for instance a red-brown colour would indicate mud,
a dull silver would indicate a scratch and a bright faceted silver
would indicate a crack. A contrast about an outline of the top
drive system and parts thereof, such as bails, links and rams and a
change in the outline can be used to check for deformation.
[0181] FIGS. 21 and 22 show an iron roughneck system 600 in
accordance with the present invention comprising an iron roughneck
601, showing a first step in the operation of connecting drill
pipe. The iron roughneck 601 is arranged on a carriage 620 which is
movably connected for up/down vertical movement to a pillar 614 and
which can also translate horizontally on a rig floor 111 for
movement toward and away from a drill pipe D of a drill string DS
in a well W. The drill string D is at well centre. Support arms 622
each side of the apparatus 10 and two support arms 624 are
pivotably connected at one end to a base 23 of the carriage 620 and
at their other ends to a support 625. Optionally, only one support
arm is used or two arms in parallel are used. The pillar 614 is
arranged on a rotatable platform 629 on rig floor 111.
[0182] The iron roughneck 610 has a torque wrench 602 and a spinner
612 connected to a spin wrench carriage 627 and arranged on the
support 625 and, are movable by a power mechanism PM toward and
away from the pillar 614 by moving the support arms 622, 624. A
console CS communicates by wire or wirelessly with the torque
wrench 602, carriage 625 and spinner 612 and/or is located remotely
from it, such as from the dog house C. The iron roughneck 610 is
able to move horizontally using foldable arms in the form of an
expandable and contractable parallelogram structure and vertically
on the pillar 614 and is movable simultaneously so that the spinner
and torquing apparatus can be aimed at a specific point and move in
a vertical plane to the joint which saves time.
[0183] A health check camera 630 is mounted on top of pillar 614
with a field of view of the top of iron roughneck 601. A health
check camera 631 and 632 is mounted either side of the iron
roughneck 601 on a part of derrick 110 having a field of view of
each side of the iron roughneck 601.
[0184] A multiplicity of reference top drive side view image is
stored on the master computer control system 250 of the iron
roughneck 601 in a stationary position. The reference iron
roughneck 601, top and side view images are preferably taken by
each camera 630, 631 and 632 from the same fixed point on the
pillar 614 and derrick 111 of a previously manually inspected view
to ensure the reference image is of the iron roughneck 601 in full
working order. The working iron roughneck 601 top and side view
images is compared to the reference iron roughneck 601 top and side
view images. If the working iron roughneck 601 top and side view
image is significantly different to the reference iron roughneck
601 top and side view images, the master computer control system
250 sends a signal to a iron roughneck 601 system controller to
cease operations.
[0185] As an additional step or an alternative to the cease
operation command, a signal is sent to an operative in accordance
with a health check system, as set out below. If the reference iron
roughneck 601 top and side view images are substantially the same
as the working iron roughneck 601 top and side view images, the
master computer control system 250 sends a signal to the iron
roughneck 601 system controller (not shown) allowing continued
operation of the iron roughneck 601.
[0186] It is envisaged that other equipment may be monitored for
health checks using cameras preferably to create a 3D digitised
image, such as travelling blocks and crown blocks, which are not
easy for rig hands to access for manual checks. A flow diagram is
shown in FIG. 23 which sets out a series of steps carried out to
carry out a health check of the present invention.
[0187] The master control computer system 100 and 250 decides which
operative to send a signal using a hierarchical management system
of the type disclosed in WO 2004/012040 which discloses a method
for controlling operation of a drilling rig using a control
management system for controlling a resource module, the method
comprising the steps of:
[0188] a) programming said control management system with at least
one set of operating parameters, said at least one resource module
having at least one operating model having at least one set of
programmed operating rules related to the at least one set of
operating parameters;
[0189] b) providing access to a plurality of users;
[0190] c) providing a set of authenticating rules to authenticate
at least one user;
[0191] d) providing hierarchical access to said at least one user
to said at least one resource module;
[0192] e) allowing said at least one user, to input an adjusted
value for at least one of the set of operating parameters in the at
least one resource module;
[0193] f) comparing said adjusted value to said at least one set of
programmed operating rules and allowing adjustment if said adjusted
value is within said operating rules;
[0194] g) providing an indication if said adjusted value is not
within said operating rules; and
[0195] h) providing a supervisor override to prevent acceptance of
said adjusted value.
[0196] A health check system is disclosed in WO 2004/044695, which
discloses a method for monitoring and analysing a plurality of
signals from monitors on at least one first drilling rig of a
plurality of drilling rigs, the method comprising: providing a
plurality of monitors for monitoring a status of a first drilling
rig in a system of a plurality of drilling rigs; monitoring with
the plurality of monitors information indicative of events at the
first drilling rig; transmitting signals from the monitors
indicative of the information to a processor on the first drilling
rig, the processor including a set of health check rules for health
checks comprising logical rules, inputs and outputs for defining
events associated with the status of the first drilling rig;
determining with the processor a severity code for each event;
reporting the events and severity codes with the processor to a
central server, the events reported by the processor to the central
server in a protocol defining a data structure, the data structure
comprising a hierarchical tree node structure wherein results from
application of the health check rules are a bottommost node of the
tree node structure; and displaying the event severity codes on a
display.
[0197] Thus the invention provides a smart floor, a derrick system
for zone management for clash avoidance and to reduce the
likelihood of items being dropped.
[0198] The invention resides in using camera technology to create a
3D realtime model of the drillfloor derrick system and use this 3D
realtime model as a basis for the zone management system. This will
also not only fixed installed machines in the rig floor and derrick
area to be part of a zone management system but also any equipment
or human that is entering this area. Also the 3D real time model
will be compared to the original 3D model of the equipment and will
be used to check for deviations and abnormalities and would serve
as an early warning for potential for dropped parts thereof of
items held by the equipment.
[0199] This means that any additional machines or humans are not
included in the zone management system.
[0200] Safe Derrick System will be based on on a 3D realtime model
being created from the camera covering the areas and this 3D model
will be used to allow the movements or not in the area. Also to the
3D model will be used to check for abnormalities on the machines or
in the system in order to prevent DROPS or other unintended
events.
[0201] Cameras will be placed in the area to provide sufficient
info to re-create a 3D image of the rig floor and derrick areas,
from the cameras a realtime 3D model of the area will be created
and used to product if a movement of the machine is safe or not.
This will also allow temporary equipment and humans in the area to
be part of the zone management system. The 3D model will be coupled
with the rig control system to have control/verification of
movements, speeds etc.
[0202] The system will also be used to verify exterior of the
machines original shape, this can be used to give warning on
potential loose items and deformation on the machines and prevent
potential dropped items and other unsafe events.
[0203] Preferably, data obtained from the images are mapped into a
three dimensional representation of the rig floor at the time. A
minimum of one image is required; however more are combined to
increase the robustness and certainty of the results.
[0204] In another embodiment, an articulated mount for the camera
is activated based on desired views and positioning of other
movable tools. The articulated mount will go to predefined
positions according to the finger configuration the column racker
will face at the time. Some models and/or fingerboard
configurations would not require additional degrees of freedom.
[0205] A camera may be mounted on a dedicated movable track.
[0206] In a particular embodiment a non-contact range sensor is
used in addition or in substitution to the image-based recognition
system. The sensor comprises a laser or sonar for the creation of a
three dimensional representation of the equipment on and around the
rig floor.
* * * * *